Child restraint

ABSTRACT

A child restraint includes a seat bottom and a seat back coupled to the seat bottom. The seat back includes a backrest configured to extend upwardly from the seat bottom and a headrest coupled to the backrest for supporting a head of a child. The headrest includes a rear section arranged along the backrest, a first side section extending outwardly away from the rear section, and a second side section extending outwardly away from the rear section and away from the first side section.

PRIORITY CLAIM

This application claims priority under 35 U.S.C. § 119(e) to U.S.Provisional Application Ser. No. 63/215,069, filed Jun. 25, 2021, whichis expressly incorporated by reference herein.

BACKGROUND

The present disclosure relates to a child restraint, and particularly toa child restraint configured to be secured to a vehicle seat within avehicle. More particularly, the present disclosure relates to a childrestraint that is configured to reduce undesirable forces acting on achild in the child restraint during operation of vehicle.

SUMMARY

According to the present disclosure, a child restraint includes a seatbottom and a seat back coupled to the seat bottom. The seat backincludes a backrest configured to extend upwardly from the seat bottomand a headrest coupled to the backrest for supporting a head of a child.The headrest includes a rear section arranged along a forward-facingsurface of the backrest, a first side section extending outwardly awayfrom the rear section, and a second side section extending outwardlyaway from the rear section and away from the first side section.

In illustrative embodiments, the child restraint further includesenergy-redirection means coupled to the first and second side sections.The energy-redirection means redirect at least a portion of a cumulativeforce from the head of the child during an impact event into at least afirst force extending into one of the first and second side sections anda second force extending outwardly away from the rear section of theheadrest so that the head of the child does not experience thecumulative force when impacting the one of the first and second sidesections. The first and second forces are each less than the cumulativeforce as a result of the head of child impacting the energy-redirectionmeans.

In illustrative embodiments, the energy-redirection means includes atleast one energy-redirection layer that is coupled to both the firstside section and the second side section. The energy redirection layerhas an outer, energy-redirection surface that faces toward the head ofthe child. The energy-redirection surface may be convexly-shapedrelative to the head of the child. During a lateral impact event, theenergy-redirection layer causes the head of the child to roll across theenergy-redirection surface and to maintain contact with theenergy-redirection surface for a longer period of time and/or distanceduring the lateral impact event. This disperses forces acting on thehead of the child over a greater area and longer period of time therebyreducing the potential for a cumulative force that may injure the child.

Additional features of the present disclosure will become apparent tothose skilled in the art upon consideration of illustrative embodimentsexemplifying the best mode of carrying out the disclosure as presentlyperceived.

BRIEF DESCRIPTIONS OF THE DRAWINGS

The detailed description particularly refers to the accompanying figuresin which:

FIG. 1 is a perspective view of a child restraint, in accordance withthe present disclosure, including a seat bottom and a seat back coupledto the seat bottom, the seat back including a backrest and a headrest,and showing that the headrest includes a rear section and left and rightside sections, each side section including a support base, a comfortlayer, and an energy-redirection layer or insert that may be added tothe headrest to increase side impact force dampening by providingenergy-redirection means for a head of a child during a collision event;

FIG. 2 is a perspective view of the headrest shown in FIG. 1 without theenergy-redirection layer and suggesting that a side impact experiencedby the child may result in a cumulative lateral force on the side wingof the headrest;

FIG. 3 is a perspective view of the headrest shown in FIG. 1 with theenergy-redirection layer installed on the headrest and suggesting thatthe energy-redirection layer is configured to redirect or separateforces imparted on the side wing by the child's head into at least afirst force extending laterally into the side section of the headrestand a second force extending outwardly away from the rear section of theheadrest so that the child does not experience the cumulative force whenimpacting the side section;

FIG. 4 is a perspective view of one of the energy-redirection layersshowing that the energy-redirection layer includes a convex outersurface configured to support the head of the child during the lateralcollision event, a rear surface configured to interface with one of theside sections of the headrest, and a chamfered surface configured tointerface with the rear section of the headrest;

FIG. 5 is a rear view of the energy-redirection layer of FIG. 4 ;

FIG. 6 is a cross-sectional view of the energy-redirection layer takenalong line 6-6 in FIG. 4 showing that the energy-redirection layer has athickness that decreases from an upper end of the energy-redirectionlayer to a lower end of the energy-redirection layer;

FIG. 7 is a cross-sectional view of the energy-redirection layer takenalong line 7-7 in FIG. 4 showing the shape of the energy-redirectionlayer that provides the convex outer surface, the rear surface, and thechamfered surface;

FIG. 8 is a cross-sectional view of the headrest from FIGS. 1-3 showingthe support layer, the comfort layer, and the energy-redirection insertsinterfacing with one another;

FIG. 9 is a cross-sectional view of another headrest, in accordance withthe present disclosure, including a support layer and a one-piece,energy-redirection insert that provides both comfort andenergy-redirection means for the head of a child; and

FIG. 10 is a cross-section view of another headrest, in accordance withthe present disclosure, which is formed as one piece from a plasticmaterial and that is formed to include a left and a right side sectionhaving an outwardly-facing convex surface that providesenergy-redirection means for the head of a child

FIG. 11 is a perspective view of another child restraint, in accordancewith the present disclosure, the child restraint including a seat bottomand a seat back having a backrest and an integrated headrest that isfixed to the backrest and includes left and right energy-redirectionunits for redirecting the child's head during a lateral collision eventto minimize forces acting on the child's head from the child restraint;and

FIG. 12 is another perspective view of the child restraint from FIG. 11.

DETAILED DESCRIPTION

A first embodiment of a child restraint 10 in accordance with thepresent disclosure is shown in FIGS. 1-3 . The child restraint 10includes a headrest 20 including energy-redirection means or inserts 34as shown in FIGS. 1-8 . A second embodiment of a headrest 220 inaccordance with the present disclosure is shown in FIG. 9 . A thirdembodiment of a headrest 320 in accordance with the present disclosureis shown in FIG. 10 . A fourth embodiment of a headrest 420 inaccordance with the present disclosure is shown in FIGS. 11 and 12 .

The child restraint 10 includes a seat bottom 12 and a seat back 14coupled to the seat bottom 12. The seat bottom 12 and the seat back 14define a child-receiving space 16 to hold a child for transportation ina vehicle, for example. The seat back 14 includes a backrest 18 coupledto the seat bottom 12 and arranged to extend upwardly from the seatbottom 12 and the headrest 20 coupled to the backrest for supporting ahead of the child.

The headrest 20 may include a rear section 22 coupled to the backrest18, a first side section or wing 24 extending outwardly away from therear section 22, and a second side section or wing 26 extendingoutwardly away from the rear section 22 and away from the first sidesection 24. In some embodiments, the headrest 20 is movable relative tothe backrest 18. In some embodiments, the headrest 20 forms an upperpart of the backrest 18 and is integral therewith (i.e., fixed inposition relative to the backrest).

Each side section 24, 26 includes a support layer 30, a comfort layer32, and an energy-redirection layer or insert 34 as shown in FIG. 4 .The support layer 30 is illustratively a polymeric panel arrangedbetween the backrest 18 and the comfort layer 32. The comfort layer 32is, for example, a foam layer that is configured to provide cushioningfor the head of a child. The support layer 30 and the comfort layer 32establish an outer contour 40 of each side section 24, 26 that mayinteract with the head of a child during a collision event to absorbenergy from the head of a child when the headrest does not include theenergy-redirection layer 34. The energy-redirection layer 34 isconfigured to replace or rest on top of the comfort layer 32 andestablish a second outer contour 42 of the first and second sidesections 24, 26 different than the outer contour 40 provided by thecomfort layer 32.

The energy-redirection layer 34 is configured to provideenergy-redirection means for redirecting at least a portion of acumulative force 50 from the head of the child during an impact event,for example a lateral collision event, into at least a first force 52extending into one of the first and second side sections 24, 26 and asecond force 54 extending outwardly away from the rear section 22 of theheadrest 20 so that the child does not experience the cumulative force50 when impacting one of the first and second side sections 24, 26. Thecumulative force 50 extends in the same direction as first force 52 andhas a higher magnitude than first force 52 and second force 54. In someembodiments, cumulative force 50 is split or transformed into firstforce 52 and second force 54. First force 52 and second force 54 maysatisfy safety standards while cumulative force 50 would not havesatisfied the same safety standards.

The energy-redirection layer 34 may be an insert that is fitted betweenthe comfort layer 32 and an outer trim 38 of the headrest 20 or betweenthe support layer 30 and the outer trim 38. The child restraint 10 maybe retrofitted with the energy-redirection layer 34. Eachenergy-redirection layer or insert 34 is formed from a material (i.e. aplastic or foam, such as, expanded polyethylene (EPE), expandedpolypropylene (EPP), porous expanded polypropylene (P-EPP), cross-linkedexpanded polyethylene (xEPE), etc.) that does not collapse or compresssubstantially during a collision event so that the head of the childrolls along an outer surface 60 of the energy-redirection layer 34during the collision event. In some embodiments, the headrest 20 alsodoes not include any side impact air bags which tend to compress withload and may not direct the head of the child to roll along the outersurface 60.

Each of the energy-redirection layers 34 may have the followingproperties and/or characteristics shown in Table 1.

TABLE 1 Physical P- Property Unit EPE EPP xEPE EPP Average pcd 1 1.3 1.51.9 2.8 1 1.3 1.9 2.8 1.5 2.8 Density Compression psi 8 10 11 13 22 1114.5 23.5 42 6 23 Strength @ 25% Compression psi 16 18 19 22 35 19 23.533.5 54 15 35 Strength @ 50% Compression psi 38 44 49 56 75 41 45 64 11140 79 Strength @ 75% Tensile % 39 40 45 52 70 35 38 55.5 67 22 27Strength Tensile lbs/in 38 32 30 29 25 18 16 15 14 50 13 Elongation TearStrength % 12 14 16 17 21 9 10 13 16 12 19 Comp Set @ % 3 3 4 4 4 8 8 77 2 5 25% Comp Set @ % 12 14 13 12 12 16 14 12 12 6 9 50% Buoyancy pcf61.2 60.6 59.5 59.5 59.1 61 60.5 59.5 59 61 n/a Thermal (K) 0.26 0.260.24 0.24 0.24 0.24 0.24 0.24 0.24 0.25 0.265 Conductivity BTU- in/ft-hr-f Thermal (R) @ 3.9 4 4.2 4.2 4.2 4.2 4.2 4.2 4.2 4 3.8 Resistance70 F. Service Temp F. 160 160 160 160 160 212 212 212 212 185 212 Water% −1 −1 −1 −1 −1 −1 −1 −1 −1 −1 −1 Absorption Compression 1000 hr 2.5 33 3.3 3 n/a n/a n/a n/a n/a n/a Creep @ 1 psi

The properties and/or characteristics in Table 1 above were calculatedusing the test methods shown in Table 2 at the time of filing thispatent application.

TABLE 2 Physical Property Test Method Average Density ASTM-D3575 CompStrength @ 25% ASTM-D3575 Comp Strength @ 50% ASTM-D3575 Comp Strength @75% ASTM-D3575 Tensile Strength ASTM-D3575 Tensile Elongation ASTM-D3575Tear Strength ASTM-D3575 Comp Set @ 25% ASTM-D3575 Comp Set @ 50%ASTM-D3575 Buoyancy ASTM-D3575 Thermal Conductivity ASTM-C177 ThermalResistance ASTM-C178 Service Temp ASTM-D3575 Water Absorption ASTM-D3575Comp Creep ASTM-D3575

Each of the materials shown in Table 1 also passed a Flammabilty testaccording to test method FMVSS-302. Each of the materials shown in Table1 also passed a Fuel Immersion test according to test method Coast Guard(CGD-770145) Fuel B.

Each energy-redirection insert 34 may include a convex, outer,energy-redirection surface 60 providing the second outer contour 42, arear surface 62 matching the outer contour 40, and a chamfered surface64 as shown in FIGS. 6 and 7 . The outer surface 60, for example, iscurved and may cause the head of the child to roll along the outersurface 60 during the collision event to provide the first and secondforces 52, 54 rather than the cumulative force 50. The rear surface 62abuts against matches the outer contour 40 of the respective sidesection without the energy-redirection layer 34 to minimize movement ofthe energy-redirection layer 34 relative to the rest of the headrest 20.The chamfered surface 64 abuts against and interfaces with the rearsection 22. In one example, the outer surface 60 may be convex relativeto the head of the child and concave relative to the support layer 30.

Each energy-redirection layer 34 or insert has a thickness 70 thatchanges to provide the energy-redirection means as shown in FIGS. 6 and7 . For example, the thickness 70 of the energy-redirection layer 34 maydecrease from an upper end 72 to a lower end 74 of theenergy-redirection layer 34 as shown in FIG. 6 . The thickness 70 mayalso decrease from a rear end 76 to a forward end 78 of theenergy-redirection layer 34 as shown in FIG. 7 . In some embodiments,the thickness 70 decreases constantly from the upper end 72 to the lowerend 74 and/or from the rear end 76 to the forward end 78. In someembodiments, the thickness 70 decreases gradually from the upper end 72to the lower end 74 and/or from the rear end 76 to the forward end 78.In some embodiments, the thickness 70 changes gradually (i.e. increasesand decreases) from the upper end 72 to the lower end 74 and/or from therear end 76 to the forward end 78. This thickness 70 causes the head ofa child to roll across outer surface 60 and to tilt downwardly during acollision event to minimize forces acting between the headrest 20 andthe head of the child.

The energy-redirection layer 34 may change an angle of the outermostsurface of the side sections 24, 26 relative to rear section 22 comparedto comfort layer 32 or support layer 30. In some embodiments, an angle65 between the outer surface 60 of each energy-redirection insert 34 andthe rear section 22 is less than an angle 66 between an outer surface 33of the comfort layer 32 and/or an angle 68 between outer surface 31 ofthe support layer 30 and the rear section 22 as shown in FIG. 8 . Theouter surface 60 of each energy-redirection insert 34 may besubstantially planar or may have a convexly-shaped outer contour 42 assuggested in FIG. 8 .

Another embodiment of a headrest 220 that can be included in childrestraint 10 in place of headrest 20 and energy-redirection inserts 34is shown in FIG. 9 . The headrest 220 is similar to headrest 20.Accordingly, similar reference numbers in the 200 series are used toindicate similar features between headrest 220 and headrest 20. Thedisclosure for headrest 20 is hereby incorporated by reference hereinfor headrest 220.

The headrest 220 includes a support layer 230 and an energy-redirectionlayer 234 as shown in FIG. 9 . The support layer 230 may be made from arigid plastic material, such as polypropylene sheeting or molded highimpact rated resin, to support the head of a child seated on the childrestraint 10. The energy-redirection layer 234 may be made from a foammaterial to provide both comfort and energy-redirection means for achild's head. Both the support layer 230 and the energy-redirectionlayer 234 provide portions of a rear section 222 and side sections 224,226 of the headrest 220.

The energy-redirection layer 234 may replace a comfort layer(s) (i.e.comfort layer 32) previously included in the headrest 20 while alsoproviding energy-redirection means. The energy-redirection layer 234 hasan outer, energy-redirection surface 260 that interacts with the head ofthe child to provide the comfort and the energy-redirection means. Theouter surface 260 of the energy-redirection layer 234 is convexly-curvedto gradually decrease an angle of the outer surface 260 of each sidesection 224, 226 relative to the rear section 222 as the outer surface260 extends away from the rear section 222.

A thickness 270 of the energy-redirection layer 234 decreases in eachside section 224, 226 as the energy-redirection layer 234 extends awayfrom the rear section 222. The thickness 270 may decrease graduallyand/or constantly from the rear section 222 to a distal end of each sidesection 224, 226. The thickness 270 may change gradually from the rearsection 222 to the distal end of each side section 224, 226. Forexample, the thickness 270 may first increase from the rear section 222to a point about midway between the rear section 222 and the distal endand then decrease from the point to the distal end of each side section224, 226. In some embodiments, the outer surface 260 of theenergy-redirection layer 234 is substantially planar.

Another embodiment of a headrest 320 that may be included in childrestraint 10 in place of headrest 20 and energy-redirection inserts 34is shown in FIG. 10 . The headrest 320 is similar to headrest 20.Accordingly, similar reference numbers in the 300 series are used toindicate similar features between headrest 320 and headrest 20. Thedisclosure for headrest 20 is hereby incorporated by reference hereinfor headrest 320.

The headrest 320 is formed as a one-piece component that includes a rearsection 322 and left and right side sections 324, 326 as shown in FIG.10 . The headrest 320 may be made from a rigid plastic material tosupport the head of a child seated on the child restraint 10 and that isshaped to provide energy-redirection means for the head of the child. Insome embodiments, the headrest 320 may be made from a foam material toprovide both comfort and energy-redirection means for a child's head orcombinations of foam and rigid plastic material.

The side sections 324, 326 each have an outer, energy-redirectionsurface 360 that interacts with the head of the child to provide thecomfort and/or the energy-redirection means. The outer surface 260 ofthe headrest 320 is convexly-curved to gradually decrease an angle ofthe outer surface 360 of each side section 324, 326 relative to the rearsection 322 as the outer surface 360 extends away from the rear section322.

A thickness 370 of each side section 324, 326 decreases as each sidesection 324, 326 extends away from the rear section 322. The thickness270 may decrease gradually and/or constantly from the rear section 322to a distal end of each side section 324, 326. The thickness 370 maychange gradually from the rear section 322 to the distal end of eachside section 324, 326. For example, the thickness 370 may first increasefrom the rear section 322 to a point about midway between the rearsection 322 and the distal end and then decrease from the point to thedistal end of each side section 324, 326. In some embodiments, the outersurface 360 of each side section 324, 326 is substantially planar.

Another embodiment of a child restraint 400 with an integrated headrest420 is shown in FIGS. 11 and 12 . Similar reference numbers in the 400series are used to indicate similar features between child restraint 400and child restraint 10. The disclosure for child restraint 10 is herebyincorporated by reference herein for child restraint 400.

The child restraint 400 includes a seat bottom 412 and a seat back 414.The seat back 414 includes a backrest 418 and a headrest 420 coupled tothe backrest 418. The headrest 420 is integrated into backrest 418 ofthe child restraint 400 so as to be mounted to the backrest 418 in afixed position. The headrest 420 includes first and second side sections424, 426. Each side section 424, 426 has a convexly-shaped,energy-redirection surface 460 that interacts with the head of thechild. The energy-redirection surface 460 provides an outer contour 442of the headrest that minimizes forces acting on the head of the childduring a collision event. The headrest 420 may be covered with a trimand/or soft goods or foam to increase comfort for the child.

The child restraints 10, 200 were tested in a side impact simulator todetermine head injury criterion of the child. The child restraintshaving side section outer contour 40 received a Head Injury Criterion(HIC) score of about 700. Unexpectedly, changing the outer contour 40 tosecond outer contour 42 using energy-redirecting layer surface 60, 260,360, 460 decreased the HIC score by more than 50% to about 321. It waspreviously thought that providing a surface such as surface 60, 260,360, 460 would adversely affect the HIC score.

1. A child restraint comprising a seat bottom, a seat back coupled tothe seat bottom and including a backrest configured to extend upwardlyfrom the seat bottom and a headrest coupled to the backrest forsupporting a head of a child, the headrest including a rear sectionarranged along the backrest, a first side section extending outwardlyaway from the rear section, and a second side section extendingoutwardly away from the rear section and away from the first sidesection, and energy-redirection means coupled to the first and secondside sections for redirecting at least a portion of a cumulative forcefrom the head of the child during an impact event into at least a firstforce extending into one of the first and second side sections and asecond force extending outwardly away from the rear section of theheadrest so that the head of the child does not experience thecumulative force when impacting the one of the first and second sidesections.
 2. The child restraint of claim 1, wherein theenergy-redirection means includes a first insert coupled to the firstside section of the headrest and a second insert coupled to the secondside section of the headrest.
 3. The child restraint of claim 2, whereinthe first and second side sections have a first outer contour and thefirst and second inserts are arranged to overlie the first and secondside sections and have a second outer contour that provides theenergy-redirection means.
 4. The child restraint of claim 1, wherein thefirst and second side sections of the headrest have an outer contourthat provides the energy-redirection means.
 5. The child restraint ofclaim 1, wherein each side section of the headrest includes a supportlayer and an energy-redirection layer arranged to lie on a forward sideof the support layer to face toward the head of the child and that hasan outer surface that provides the energy-redirection means.
 6. Thechild restraint of claim 5, wherein the outer surface of theenergy-redirection layer is a convexly-shaped surface relative to thehead of the child.
 7. The child restraint of claim 6, wherein theenergy-redirection layer has a thickness that changes as theenergy-redirection layer extends away from the rear section toward adistal end of a corresponding side section.
 8. The child restraint ofclaim 6, wherein the energy-redirection layer has a thickness thatdecreases as the energy-redirection layer extends away from the rearsection toward a distal end of a corresponding side section.
 9. Thechild restraint of claim 8, wherein the thickness decreases as theenergy-redirection layer extends from an upper end of theenergy-redirection layer to a lower end of the energy-redirection layer.10. The child restraint of claim 1, wherein the headrest is movablerelative to the backrest.
 11. The child restraint of claim 1, whereinthe headrest forms an upper part of the backrest.
 12. A child restraintcomprising a seat bottom and a seat back coupled to the seat bottom andincluding a backrest configured to extend upwardly from the seat bottomand a headrest coupled to the backrest for supporting a head of a child,the headrest including a rear section arranged along the backrest, afirst side section extending outwardly away from the rear section, and asecond side section extending outwardly away from the rear section andaway from the first side section, wherein the first side section and thesecond side section each include an outer energy-redirection surfacethat is configured to redirect a cumulative force from the head of thechild during a lateral impact event into at least a first forceextending into one of the first and second side sections and a secondforce extending outwardly away from the rear section of the headrest sothat the head of the child does not experience the cumulative force whenimpacting the one of the first and second side sections, the first andsecond forces each being less than the cumulative force.
 13. The childrestraint of claim 12, wherein the first and second side sections eachinclude a support layer coupled to the backrest, a comfort layer coupledto the support layer and an energy-redirection layer that overlies thecomfort layer when installed to provide the outer, energy-redirectionsurface of at least one of the first and second side sections.
 14. Thechild restraint of claim 13, wherein the comfort layer has a first outercontour in each side section and each energy-redirection surface has asecond outer contour different than the first outer contour.
 15. Thechild restraint of claim 14, wherein the second outer contour isconvexly shaped relative to the head of the child.
 16. The childrestraint of claim 12, wherein each side section of the headrestincludes a support layer and an energy-redirection layer arranged to lieon a forward side of the support layer to face toward the head of thechild to provide the outer, energy-redirection surface.
 17. The childrestraint of claim 16, wherein the energy-redirection layer has athickness that changes as the energy-redirection layer extends away fromthe rear section toward a distal end of a corresponding side section.18. The child restraint of claim 16, wherein the energy-redirectionlayer has a thickness that decreases as the energy-redirection layerextends away from the rear section toward a distal end of acorresponding side section.
 19. The child restraint of claim 18, whereinthe thickness decreases as the energy-redirection layer extends from anupper end of the energy-redirection layer to a lower end of theenergy-redirection layer.
 20. The child restraint of claim 19, whereinthe headrest is movable relative to the backrest.